Eccentric fold, pressure-seal mailer with built-in envelope

ABSTRACT

A single ply mailer is provided configured for double folding into, for instance, a V-configuration, that provides a built-in return or reply envelope and a lip portion that serves to permit easy opening of the mailer when assembled.

RELATED PRIOR APPLICATION

This application claims priority to provisional patent application Ser. No. 60/514,567, filed Oct. 27, 2003, which is incorporated herein in its entirety by reference.

FIELD OF THE INVENTION

The invention relates to a single ply mailer having a built-in envelope that allows for simplex printing.

BACKGROUND OF THE INVENTION

Many business forms are constructed as mailers that are used for a variety of purposes including sending information via the U.S. Postal Service to addressees and other recipients who may have interest in such information. The mailers may embody advertising and marketing materials, invoices and billing statements, financial and bank statements, registration forms and any other types of information and data that may be useful to addressees or intended recipients. Prior art mailers typically constitute two types of designs including continuous business forms and cut sheet business forms. Continuous business forms include a series of mailers that are connected together by a single ply of continuous paper or web or a number of superimposed plies that similarly form a continuous paper or web. The continuous paper or web is processed via a number of processes including printing, folding and gluing. During such processing individual mailers are cut from the continuous paper or web to form individual mailers. In contrast, cut sheet business forms are individual mailers formed of a singly ply or multiple superimposed plies that are processed separately.

Many continuous and cut sheet business form designs include an envelope disposed within an interior of a mailer that may serve, for instance, as a return envelope configured to receive a variety of forms, such as a coupon, a payment stub, a registration form or other insert, to be returned to the sender of the mailer. In many cases, envelopes of prior art designs include one or more panels adhered to a body of a base mailer to form an envelope within the interior of the mailer when it is assembled. Such mailers require additional plies to be added to the base mailer, e.g., adhered to the base mailer with various strips or dots of adhesive disposed along certain portions of the base mailer, to form the envelope, as well as require one or more tabs or panels to form and/or to seal the envelope for use. Such designs typically involve a number of steps in a production process and utilize additional panels of a substrate such a paper from which the mailer is formed. In other cases, envelopes are created by folding the bottom panel similar to a “C-fold” construction. Such mailers require either duplex imaging or the use of a window to have the outgoing address on the outgoing envelope while variable information is secured inside the closed mail piece.

SUMMARY OF THE INVENTION

An object of the invention is to provide an improved mailer. Another object of the invention is to provide an improved mailer having an internal, built-in envelope. A further object of the invention is to provide a single ply, multi-fold mailer that forms a built-in envelope as a consequence of folding the single ply. Still another object of the invention is to provide a single ply mailer defining four panels that form a built-in envelope as a consequence of folding along certain fold lines and adhering certain strips or dots of adhesive. Yet another object of the invention is to provide a single ply form that is capable of being simplex imaged having images along an outgoing envelope portion, a reply envelope portion and along a statement or stub portion.

In general, in an aspect, the invention provides a mailer that is capable of simplex imaging without use of a window by providing an outgoing address and a stub on the same side or surface of a single ply or sheet of paper, a document or other substrate. In addition, the invention provides a mailer with a generic return envelope formed within its interior when assembled that may be simplex imaged at the same time as an outgoing envelope, which provides billing and mailing services to reduce inventory without the increased costs of duplex imaging. The mailer according to the invention may be simplex imaged with either one of its outer edges, e.g., a first or top edge or a second or bottom edge with respect to the length of the mailer, serving as a top edge of the mailer to orient graphics and/or fonts in a manner that helps to support a mailer design and/or a laser printer. Further, the mailer according to the invention supports imaging a “return address” along a reply envelope portion of the mailer that allows an end-user's or recipient's name and/or account number or other information to be identified along the reply envelope portion to provide such information to the sender, e.g., in the event the end-user or recipient does not include, for instance, a return insert, coupon or stub that bears such information. The invention further provides a mailer that is constructed of a single ply or sheet that is substantially flat to thereby help to reduce or eliminate a raised stack height and related problems that are associated with patch reply envelopes when a plurality of mailers according to the invention are stacked, e.g. one on top of another.

Various aspects of the invention provide one or more of the following capabilities. A single ply, multi-fold mailer is provided that includes a built-in envelope such that upon opening and unfolding the mailer when assembled, the envelope is intact and freestanding for use. A single ply mailer is configured for use with an in-line production process, which includes printing information and indicia along one or more surfaces of the mailer and folding the mailer along a number of fold lines and along a number of strips or dots of adhesive, to form the mailer and to define a built-in envelope within the interior of the mailer. A single ply, multi-fold mailer is provided that can help to reduce manufacturing costs.

These and other capabilities of the invention, along with the invention itself, will be more fully understood after a review of the following figures, detailed description, and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a first surface of a mailer according to one aspect of the invention illustrating four panels;

FIG. 2 is a plan view of a second surface of the mailer shown in FIG. 1 illustrating four opposing panels;

FIG. 3 is a plan view of the first surface of the mailer shown in FIG. 1 illustrating various fold lines and lines of weakening;

FIG. 4 is a plan view of the first surface of the mailer shown in FIG. 1 illustrating overall dimensions;

FIG. 5 is a plan view of the first surface of the mailer shown in FIG. 1 illustrating other overall dimensions;

FIG. 6 is a plan view of the first surface of the mailer shown in FIG. 1 illustrating still further overall dimensions;

FIG. 7 is a plan view of the first surface of the mailer shown in FIG. 1 illustrating positions of strips or dots of adhesive;

FIG. 8 is a plan view of the second surface of the mailer shown in FIG. 2 illustrating positions of strips or dots of adhesive;

FIG. 9 is a plan view of the first surface of the mailer shown in FIG. 1 with additional positions of strips or dots of adhesive;

FIG. 10 is a perspective view of folding the mailer shown in FIG. 1 along one set of fold lines;

FIG. 11 is a perspective view of folding the mailer shown in FIG. 10 along a second set of fold lines;

FIG. 12 is a plan view of the mailer shown in FIG. 11 fully assembled and partially torn along lines of weakness;

FIG. 13 is plan view of the mailer shown in FIG. 12 unfolded along one set of fold lines;

FIG. 14 is a plan view of the mailer shown in FIG. 13 with a panel partially removed therefrom;

FIG. 15 is a plan view of the mailer shown in FIG. 14 with a second panel partially removed therefrom;

FIG. 16 is a plan view of a freestanding, built-in envelope of the mailer shown in FIG. 15; and

FIG. 17 is a plan view of the envelope shown in FIG. 16 with a portion of one of the panels removed being inserted therein.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Embodiments of the invention provide a mailer constructed as a multi-fold, single unit for use in distribution of information and data of potential interest to recipients of the mailer. A mailer according to the invention is a single ply or sheet including four panels and multiple parallel fold lines traversing the panels, and further includes multiple strips or dots of adhesive disposed longitudinally along certain portions of the panels. Folding panels along certain fold lines and mating certain strips or dots of adhesive help to form an assembled mailer. In one aspect, the mailer according to the invention includes multiple parallel fold lines to permit the single ply to doubly fold to form, for instance, a double V-fold configuration of the mailer. In addition, the mailer according to the invention further includes a built-in envelope or other insert disposed within the mailer and configured such that the envelope may be used when the mailer is opened or unfolded. Other embodiments are within the scope of the invention.

The term “adhesive” used to disclose various aspects of the invention refers to an adhesive or cohesive that is activated or provides cohesion to adhere to a surface with an application of a pressure or force to the adhesive or cohesive. Such adhesives and cohesives also include re-sealable adhesives and cohesives. In addition, the term adhesive can also refer to a wettable or rewettable adhesive or cohesive that is activated for adhesion with an application of moisture or water.

Referring to FIGS. 1 and 2, in one aspect, the invention provides a mailer 101 including a first surface 1 and a second surface 2. In one configuration, the first surface 1 is configured to be printed with information and images including address information and other information and data of potential interest to a recipient of the mailer 101. The first surface 1 serves primarily as an outer surface of the mailer 101 when the mailer 101 is assembled. The second surface 2 is also configured to be printed with information and images and may also include information and data. The second surface 1 serves primarily as a second or interior surface of the mailer 101 when the mailer 101 is assembled.

In one configuration, the mailer 101 is formed of a single ply or sheet of paper or other substrate constructed for printing by any of a variety of printers and methods or techniques well known in the art. In particular, the mailer 101 may be formed as a single ply or sheet from a continuous paper web or other substrate that may be used, for instance, in a continuous printing process that is incorporated in-line with a production and assembly method of the mailer 101 whereby the mailer 101 is cut from the continuous web during one phase of production.

Referring to FIG. 3, and with further reference to FIGS. 1 and 2, in one configuration, the mailer 101 includes four panels 2, 4, 5 and 7 whose surfaces comprise the first surface of the mailer 101. As shown in FIGS. 1 and 3, each panel 2, 4, 5 and 7 is defined by multiple parallel fold lines that traverse the panels 2, 4, 5 and 7 horizontally along a width of each panel 2, 4, 5 and 7. A first or top panel 2 is defined between a first or top outer edge 102 of the mailer 101 and a first fold line 18. A second or middle panel 4 and a third or middle panel 5 are disposed adjacent to the first or top panel 2. The second or middle panel 4 is defined between the first fold line 18 and a second fold line 19. The third or middle panel 5 is defined between the second fold line 19 and a third fold line 20. A fourth or bottom panel 7 is defined between a fourth fold line 21 disposed just below the third fold line 20, as shown in FIGS. 1 and 3, and a second or bottom outer edge 103 of the mailer 101.

As shown in FIG. 2, fold lines 18′, 19′, 20′ and 21′ defined along the second surface 2 of the mailer 101 are disposed at positions that correspond to the fold lines 18, 19, 20 and 21 defined along the first surface 1. The corresponding fold lines 18′, 19′, 20′ and 21′ similarly define multiple panels 10, 11, 12, and 14 whose surfaces form the second surface 2 of the mailer 101. The multiple panels 10, 11, 12 and 14 are essentially the opposite surfaces of the panels 2, 4, 5 and 7 along the first surface 1. A first or top panel 10 is defined between the first or top outer edge 102 of the mailer 101 and a first fold line 18′. A second panel 11 is defined between the first fold line 18′ and a second fold line 19′ defined along the second surface 2. A third panel 12 is defined between the second fold line 19′ and a third fold line 20′, and a fourth panel 14′ is defined between a fourth fold line 21′ disposed just below the third fold line 20′ and the second or bottom outer edge 103 of the mailer 101.

The fold lines 18, 19, 20 and 21 along the first surface 1 and the fold lines 18′, 19′, 20′ and 21′ along the second surface 2 help to permit the mailer 101 to fold along a width of the mailer 101 to form a required or desired configuration. The fold lines 18, 19, 20 and 21 and 18′, 19, 20 and 21 may include printed lines or other demarcations to identify the axes traversing the width of the mailer 101 along which the mailer 101 is to be folded. Alternatively, or in addition, one or more of the fold lines 18, 19, 20 and 21 and 18′, 19′, 20′ and 21′ may include lines of weakness, embossing or lines of perforations defined in the mailer 101 that help to facilitate folding of the mailer 101 along one or more of the fold lines 18, 19, 20 and 21 and 18′, 19′, 20′ and 21′ and/or to facilitate removal of one or more of the panels 2,10 and 4, 11 and 5, 12 and 7,14 from the mailer 101, as will be described below in more detail. In one configuration, the lines of perforations that serve as one or more of the fold lines 18, 19, 20 and 21 and 18′, 19′, 20′ and 21′ are not through perforations defined from the first surface 1 to the second surface 2.

With further reference to FIGS. 2 and 3, a first longitudinal line of weakness 15 is defined along the mailer 101 adjacent to a first side edge 104. The line of weakness 15 bounds an area 43 between the first side edge 104 and the line of weakness 15. As will be described below in more detail, one or more strips or dots of adhesive are disposed along the area 43. A second longitudinal line of weakness 16 is defined along the mailer 101 adjacent to a second side edge 105, and bounds an area 42 between the second side edge 105 and the line of weakness 16. Similarly, as will be described below, one or more strips or dots of adhesive are disposed along the area 42. The longitudinal lines of weakness 15 and 16 are disposed and configured to permit an end-user to tear the mailer 101 along the lines weakness 15 and 16 to open the mailer 101 as required or desired when the mailer 101 is assembled. The first and the second longitudinal lines of weakness 15 and 16 may include lines of embossing and/or lines of perforations that are defined along the surfaces 1 and 2 to facilitate tearing along the lines l5 and 16 to unfold the mailer 101. In one configuration, the lines of weakness 15 and 16 include lines of embossing and/or lines of perforations that extend from the first surface 1 through to the second surface of the mailer 101. In addition, printed lines or other demarcations may be used to further identify the lines of weakness 15 and 16 and to indicate the lines 15 and 16 along which the assembled mailer 101 is to be torn to unfold the mailer 101 as required or desired.

With further reference to FIG. 2, an area defined between the third fold line 20′ and the fourth fold line 21′ along the second surface 2 includes an area or strip 13 between the third panel 5,12 and the fourth panel 7, 14 that has one or more strips or dots of adhesive 13′, such as re-wettable adhesive, to help to permit portions of the mailer 101, e.g., the second panel 4, 11 and the third panel 5, 12, to serve as a built-in envelope or other insert disposed within the interior of the mailer 101 when the mailer is 101 assembled, as will be described below in more detail. The one or more strips or dots of adhesive 13′ help the area 13 to serve as an over flap to seal the built-in envelope and to secure any contents therein.

Referring to FIGS. 4, 5 and 6, dimensions of configurations of the mailer 101 according to the invention are illustrated. As shown in FIG. 4, in one configuration, the mailer 101 includes overall dimensions measuring a length L₁ of about 14 inches and a width W₁ of about 8.5 inches. A further configuration of the mailer 101 shown in FIG. 5 includes the mailer 101 having a length L₂ of about 17 inches and a width W₂ of about 8.5 inches. Another configuration of the mailer 101 is shown in FIG. 6 including a length L₃ of about 17 inches and a width W₃ of about 11 inches. A length (or height) of each panel 2, 4, 5 and 7 and 10, 11, 12 and 14 of the mailer 101 shown in FIG. 5 that defines a length L₂ of about 17 inches is substantially the same as a length (or height) of each panel 2, 4, 5 and 7 and 10, 11, 12 and 14 of the mailer 101 shown in FIG. 6 that defines a length L₃ of about 17 inches. The dimensions of the mailer 101 illustrated in FIGS. 4, 5 and 6 are instances of preferred dimensions.

The invention is not limited to these dimensions of the mailer 101 or of the panels 2, 4, 5 and 7 and 10, 11, 12 and 14, and envisions that the mailer 101 and each panel 2, 4, 5 and 7 and 10, 11, 12 and 14 can define other lengths (or heights) and widths that are conducive to its position and purpose relative to the mailer 101 when the mailer 101 is assembled.

Referring to FIG. 7, positions of multiple strips or dots of adhesive are illustrated along the first surface 1 of the mailer 101. One or more strips or dots of adhesive 24 are disposed longitudinally along the area 43 adjacent to the first panel 2 defined between the line of weakness 15 and the first side edge 104 and between the first or top outer edge 102 and the first fold line 18. One or more strips or dots of adhesive 26 are also disposed adjacent to the first panel 2 and longitudinally along the area 42 defined between the line of weakness 16 and a second side edge 105 and the first or top outer edge 102 and the first fold line 18. Similarly, as shown in FIG. 7, one or more strips or dots of adhesive 25 are disposed adjacent to the second panel 4 and longitudinally along the area 43 defined between the line of weakness 15 and the first side edge 104 and between the first fold line 18 and the second fold line 19. The area 42 adjacent to the second panel 4 defined between the line of weakness 16 and the second side edge 105 and between the first fold line 18 and the second fold line 19 similarly includes strips or dots of adhesive 27 disposed longitudinally.

The strips or dots of adhesive 24, 25, 26 and 27 disposed along the areas 42 and 43 are further positioned such that when the mailer 101 is folded along the first fold line 18, in the direction indicated by arrow 200 shown in FIG. 7, the strips or dots 24 and 26 adjacent to the first panel 2 mate with the strips or dots 25 and 27 adjacent to the second panel 4. Folding the mailer 101 along the first fold line 18 also places the first panel 2 along the first surface of the mailer 101 in facing relationship and flush with the second panel 4.

With further reference to FIG. 7, additional strips or dots of adhesive 44 and 45 are disposed along the areas 42 and 43, respectively, adjacent to the second panel 4 in order to help to provide further secure attachment of the first panel 2 with the second panel 4 when folded and mated as described above.

Referring to FIG. 8, multiple strips or dots of adhesive are disposed along the second surface 2 of the mailer 101. In one configuration, the second surface 2 of the mailer 101 includes strips or dots of adhesive 31 and 32 disposed longitudinally along the area 43 defined by the first line of weakness 15 and the first side edge 104. Similarly, in this configuration, strips or dots of adhesive 29 and 30 are disposed longitudinally along the area 42 defined by the second line of weakness 16 and the second side edge 105.

Additional strips or dots of adhesive 33, 34, 35 and 36 are disposed longitudinally along each side of the second panel 11 and the third panel 12. As shown in FIG. 8, the strips or dots of adhesive 33 and 34 are disposed longitudinally in the second and third panels 11 and 12 adjacent to the first line of weakness 15 and outside of the area 43 defined between the first side edge 104 and the first line of weakness 15. In addition, the strips or dots of adhesive 35 and 36 are disposed longitudinally in the second and third panels 11 and 12 adjacent to the second line of weakness 16 and outside of the area 42 defined between the second side edge 105 and the second line of weakness 16.

The strips or dots of adhesive 33 adjacent to the second panel 4 mate with the strips or dots of adhesive 34 adjacent to the third panel 5 when the mailer 101 is folded along the second fold line 19′ in the second surface 2. Also, the strips or dots of adhesive 35 adjacent the second panel 4 mate with the strips or dots of adhesive 36 when the mailer 101 is folded along the second fold line 19′.

The strips or dots of adhesive 33, 34, 35 and 36 in the second and third panels 11 and 12 along the second surface 2 help to form an envelope within the interior of the mailer 101 from the second and third panels 4, 11 and 5, 12 when the mailer is assembled, as will be described below in more detail.

Still referring to FIG. 8, one or more strips or dots of adhesive 38 are disposed in the second surface 2 of the mailer 101 across the fourth panel 14 adjacent to the second or bottom outer edge 103. One or more strips or dots 40 are also disposed within the area 43 adjacent to the line of weakness 15 proximate to a corner or intersection of the first side edge 104 and the second or bottom outer edge 103. Similarly, one or more strips or dots 39 of adhesive are also disposed within the area 42 adjacent to the line of weakness 16 proximate to a corner or intersection of the second side edge 105 and the second or bottom outer edge 103. Although optional, the strips or dots 39 and 40 help to assemble the mailer 101 and to secure the mailer 101 when the mailer 101 is assembled by mating with the strips or dots 44 and 45, respectively, disposed along the first surface 1 of the mailer 101.

Referring in FIG. 9, in another configuration of the mailer 101, additional strips or dots of adhesive 24, 25, 26 and 27 are disposed adjacent to the first and the second panels 10 and 11 along the second surface 2. Multiple strips or dots of adhesive 24 and 25 are disposed in the area 43, and multiple strips or dots of adhesive 26 and 27 are disposed in the area 42. The strips or dots of adhesive 24 and 26 adjacent the first panel 10 mates with the strips or dots 25 and 27 adjacent the second panel 11 help to secure the mailer 101 when assembled.

The invention is not limited to the locations of the strips or dots of adhesive along the first surface 1 and the second surface 2 of the mailer 101 as shown in FIGS. 8 and 9, and anticipates that strips or dots of adhesive may be located along other portions of the first and the second surfaces 1 and 2 to help to assemble and secure the mailer 101 and to help to maintain certain panels of the mailer 101 intact when the assembly mailer 101 is tom along the lines of weakness 15 and 16 and unfolded.

Referring to FIGS. 10 and 11, formation of the mailer 101 is illustrated. In one configuration, the mailer 101 may be folded initially along the second fold lines 19 and 19′ of the first and second surfaces 1 and 2 in a direction shown by arrow 205 in FIG. 10 to place the surfaces of the first and second panels 10 and 11 in contact or flush with the surfaces of the third and fourth panels 12 and 14. In this case, the mailer 101 is essentially folded in half along the second fold lines 19 and 19′. As shown in FIG. 11, the mailer 101 is further folded along the first fold lines 18 and 18′ and the third fold lines 20 and 20′ in a direction shown by arrow 210 in FIG. 11 to place the surface of the first panel 2 in contact or flush with the surface of the second panel 4. The surfaces of the third panel 5 and the fourth 7 along the first surface 1, as a result, define the outer surfaces of the mailer 101 when the mailer 101 is assembled.

During folding of the mailer 101, as described above with reference to FIGS. 10 and 11, strips or dots of adhesive disposed along the second surface 2 are mated. Specifically, as a result of the mailer 101 being folded along the second fold lines 19 and 19′ in the direction shown by arrow 205, the strips or dots of adhesive 29 and 31 disposed along the areas 42 and 43, respectively, adjacent to the first and the second panels 10 and 11 are placed in contact or mate with the strips or dots of adhesive 30 and 32 disposed along the areas 42 and 43, respectively, adjacent to the third and the fourth panels 12 and 14. In addition, as a result of the mailer 101 being folded along the second fold lines 19 and 19′, the strips or dots of adhesive 33 and 35 disposed adjacent to the second panel 11 are placed in contact or mate with the strips or dots of adhesive 34 and 36 disposed adjacent to the third panel 12.

In one aspect of the invention, during or after the mailer 101 is folded as described above, a pressure or force is applied to the mailer 101 to help to achieve folding along the fold lines as noted, and to help to mate and adhere the strips or dots of adhesive with one another to secure the panels and to thereby assemble the mailer 101. In this case, the adhesive includes a pressure seal adhesive formulated to adhere to a surface. e.g., with adhesive disposed thereon, when a pressure or force is applied to the adhesive. The invention is not limited to pressure sensitive adhesive and envisions that other types or formulations of adhesive other than or in addition to a pressure sensitive adhesive may be used to form the mailer 101.

Still referring to FIGS. 10 and 11, and with further reference to FIGS. 4, 5 and 6, the dimensions of the panels 2,10, and 4, 11 and 5, 12 and 7, 14 may define a length or height such that the total length or height of the first and second panels 2, 10 and 4, 11 is less than the total length or height of the third and fourth panels 5, 12 and 7, 14 and the length or height of the area 13. When the mailer 101 is folded along the second fold lines 19 and 19′, as described above with reference to FIG. 10 and as shown by arrow 205, the first and second panels 2, 10 and 4, 11 contact and lay flush with the third and fourth panels 5, 12 and 7,14 such that a lip portion 50 of the fourth panel 7, 14, as will be discussed below in more detail, remains extended from the folded mailer 101 and the strips or dots of adhesive 38 along the fourth panel 14 adjacent to the second or bottom outer edge 103 are exposed. As shown in FIG. 12, the strips or dots of adhesive 38 are exposed such that the strips or dots of adhesive 28 disposed along the second panel 12 adjacent to the second fold line 19′ couple to and mate with the strips or dots of adhesive 38 when the mailer 101 is further folded along the first fold lines 18 and 18′ and the third fold lines 20 and 20′ in the direction shown by arrow 210 to help to secure the mailer 101 in its assembled configuration.

As shown in FIGS. 4, 5 and 6, the total length L₁ of the first and second panels 2,10 and 4, 11 is shorter than the total length L₂ of the third and fourth panels 5, 12 and 7, 14 that includes an area or strip 6 along the second surface 2, which is opposite to the area or strip 13 along the first surface 1. The shorter total the length L₁ of the first and second panels 2, 10 and 4, 11 helps to form a lip portion 50 along a portion of the fourth panel 7, 14 adjacent to the bottom edge 103 of the mailer 101. As shown in FIG. 11, when the mailer 101 is folded along the first fold line 18, 18′ and the third fold line 20, 20′ to accomplish a double-fold of the mailer 101 into a V-configuration, the lip portion 50 with the strips or dots of adhesive 38 disposed along the lip portion 50 mate with the strips or dots of adhesive 29 disposed along the second panel 4, 11 adjacent to the second fold line 19.

As shown in FIG. 11, when the mailer 101 is assembled, the lip portion 50 helps to serve as an opening flap along an edge 101′ of the assembled mailer 101. The lip portion 50, for instance, has sufficient length to permit an end-user or recipient of the mailer 101 to slip a portion of his/her finger between the lip portion 50 and the other panels of the mailer 101 and to permit the end-user or recipient to drag the portion of his/her finger at the lip portion 50 along at least a portion of the edge 101′ to help to disengage the strips or dots of adhesive 38 and to thereby open the mailer 101. The lip portion 50 essentially helps to insure that the mailer is opened with ease and without inappropriate tearing of the mailer 101.

With further reference to FIGS. 4, 5 and 6, the second and third panels 4,11 and 5,12 define a length that are sufficient to permit the mailer 101 to be mailed, while the length is short enough to send the mailer 101 through the U.S. Postal Service. Further, in one configuration, each of the second and the third panels 4, 11 and 5, 12 define approximately the same length in order to help to align the fold lines 18, 18′ and 20, 20′ during the second fold, as shown in FIG. 11. In general, the first panel 2, 10 may define the longest length of the mailer 101 to help to maximize an area for imaging.

In one configuration of the mailer 101, the total length L₁ may be shorter than the total length L₂ by constructing each of the first panel 2,10 and the fourth panel 7, 14 with a shorter length than the length of each of the second panel 4, 11 and the third panel 5,12. The invention envisions other configurations to render the total length L₁ shorter than the length L₂ .

Referring to FIG. 12, an assembled mailer 101 is shown with areas 42 and 43 of the assembled mailer 101 being removed as a consequence of tearing the mailer 101 along the lines of weakness 15 and 16. The folding scheme described above permits the third panel 5 and the fourth panel 7 (not shown) along the first surface 10 to form the outer or external surfaces of the mailer 101.

Referring to FIG. 13, the open mailer 101 is shown that results when the areas 42 and 43 are removed from the mailer 101 and the mailer 101 is unfolded along the first fold lines 18 and 18′ and the third fold lines 20 and 20′. The first panel 2 and the second panel 4 of the first surface 1 are thereby exposed. On the opposite side of the open mailer 101, the third panel 5 (not shown) and the fourth panel 7 (not shown) are also exposed. In addition, the strips or dots of adhesive 38 disposed along the fourth panel 14 of the second surface 2 are exposed.

As shown in FIGS. 13 and 14, in one configuration, the first panel 2 may serve as an insert, e.g., a billing statement, an order form or other information bearing configuration, disposed within the mailer 101 that is accessed when the mailer 101 is unfolded as described above. The first panel 2 may be further configured to define a portion 3 with a line of weakness 17 whereby the portion 3 can serve as a removable tab, coupon, stub or other configuration that is separated from the first panel 2 when the portion 3 is torn along the first fold lines 18 and 18′ and the line of weakness 17, as shown in FIG. 14, to remove the portion 3 from the first panel 2 and the mailer 101. In addition, the first panel 2 may be completely removed from the mailer 101 when torn along the first fold lines 18 and 18′. In this case, the first fold lines 18 and 18′ are defined as lines of weakening including, but not limited to, lines of embossing or perforations, that permit the first panel 2 to be removed from the mailer 101. As shown in FIGS. 13 and 14, the portion 3 is sized for insertion into a built-in envelope 300 formed by the second panel 4, 11 and the third panel 5, 15 when the mailer 101 is assembled and thereafter unfolded as described above. The built-in envelope 300 is described below in more detail.

With further reference to FIG. 15, when the first panel 2, 10 and the insert or tab 3 are removed from the mailer 101, the fourth panel 7, 14 is exposed and can be removed from the mailer 101 along the fourth fold lines 21 and 21′. In this case, the fourth fold lines 21 and 21″ along the first and the second surfaces 1 and 2 are lines of weakening including, but not limited to, lines of embossing or perforations, that permit the fourth panel 7, 14 to be removed from the mailer 101 when the mailer 101 is torn along the fourth fold lines 21 and 21′.

Referring to FIGS. 16 and 17, and with further references to FIGS. 14 and 15, with removal of the first panel 2, 10 and the insert or tab 3, and removal of the fourth panel 7, 14, the built-in envelope 300 results with surfaces of the second and third panels 4 and 5 exposed along the outside of the envelope 300 and surfaces of the second and third panels 11 and 12 disposed within the interior of the envelope 300. During folding of the mailer 101 as described above, the surfaces of the second and third panels 11 and 12 are placed in contact or mate with one another. In addition, the strips or dots of adhesive 33 and 35 along the surface of the second panel 11 contact or mate with the strips or dots of adhesive 34 and 36 along the surface of the third panel 12. Upon an application of force or pressure to the strips or dots of adhesive 33, 34, 35 and 36, the second panel 11 is adhered to the third panel 12. The surfaces of the adhered second and third panels 4,11 and 5, 12 define an enclosed interior bound along the strips or dots of adhesive 33, 34, 35 and 36 and the third fold line 19 and 19′. The built-in envelope 300, as shown in FIGS. 16 and 17, is thereby formed from the adhered second and the third panels 4, 11 and 5, 12.

The positions of the strips or dots of adhesive 33, 34, 35 and 36 permit the second and the third panel 4, 11 and 5, 12 to remain adhered to one another when the areas 42 and 43 are removed from the assembled mailer 101 along the lines of weakness 15 and 16 to open the mailer 101. The built-in envelope 300 thereby remains intact when the mailer 101 is opened and unfolded as described. In addition, the strips or dots of adhesive 13 located between the third fold line 20′ and the fourth fold line 21′ along the second surface 2 are exposed when the mailer 101 is opened and unfolded. Further, access to the interior of the built-in envelope 300 is provided by an opening 302 defined by the second and the third panels 4, 11 and 5, 12 that is available with the removal of the first panel 2, 10 and the tab or insert 3, as shown in FIG. 14.

As shown in FIGS. 16 and 17, when the first panel 2, 10, the insert or tab 3, and the fourth panel 7, 14 are removed from the mailer 101, the built-in envelope 300 is freestanding. The first panel 2, 10 and/or the tab 3 may be inserted into the interior of the built-in envelope 300 through the opening 302. The third panel 5, 12 may be folded along the fourth fold line 21, 21′ to contact or mate the strips or dots of adhesive 13′ with the surface of the second panel 4 to adhere the strips or dots of adhesive 13′ to the second panel 4 to thereby seal the built-in envelope 300, as shown in FIG. 17.

Depending upon the purpose or function of the built-in envelope 300, the surfaces of the second and third panel 4 and 5 along the first surface 1 may include return address information and other information or indicia, such as, for instance, a meter stamp indicating prepaid postage. In addition, the surfaces of the first panel 2 and the insert or tab 3 may include information and indicia to form, for instance, an invoice or statement, as noted above, with the insert or tab 3 being configured to serve as a payment coupon or stub for insertion into the built-in envelope 300 to be mailed along with a payment.

The invention is not limited with respect to the information and indicia printed on or otherwise displayed along the surfaces of the panels 4, 10, and 4, 11, and 5, 12 and 7, 14 and envisions such panel surfaces may include any information or indicia to serve one or more purposes. Further, the built-in envelope 300 as described herein can serve any of a number of purposes. For instance, in another aspect, the invention may provide the built-in envelope with one or more inserts contained therein.

Having thus described at least one illustrative embodiment of the invention, various alterations, modifications and improvements will readily occur to those skilled in the art. Such alterations, modifications and improvements are intended to be within the scope and spirit of the invention. Accordingly, the foregoing description is by way of example only and is not intended as limiting. The invention's limit is defined only in the following claims and the equivalents thereto. 

1. A mailer with a built-in envelope comprising: a single ply of paper defining a length between a first outer edge and a second outer edge and defining a width between a first side edge and a second side edge; a first panel defined in the single ply of paper between the first outer edge and a first fold line traversing the single ply of paper between the first and the second side edges; a second panel defined in the single ply of paper between the first fold line and a second fold line traversing the single ply of paper between the first and the second side edges; a third panel defined in the single ply of paper between the second fold line and a third fold line traversing the single play of paper between the first and the second side edges; a fourth panel defined in the single ply of paper between the third fold line traversing the single ply of paper between the first and the second side edges and a second outer edge; the first panel and the second panel defining a total length that is less than a total length of the third panel and the fourth panel; a first longitudinal line of weakening and a second longitudinal line of weakening each traversing the length of the single ply of paper between the top outer edge and the bottom outer edge; and one or more strips of adhesive disposed along at least a portion of the length of the single ply between the first side edge and the first longitudinal line of weakening, and one or more strips of adhesive disposed along at least a portion of the length of the single ply between the second side edge and the second longitudinal line of weakening; and a first set of one or more strips of adhesive and a second set of one or more strips of adhesive disposed along the second panel within an area of the second panel between the first and the second longitudinal lines of weakening, each set spaced from the other set, and a third set of one or more strips of adhesive and a fourth set of one or more strips of adhesive disposed along the third panel within an area of the third panel between the first and the second longitudinal lines of weakening, each set spaced from the other set, the third set of strips of adhesive further disposed to correspond to a position of the first set of strips of adhesive and the fourth set of strips of adhesive further disposed at positions to correspond to a position of the second set of strips of adhesive, wherein when the single ply of paper is folded along the second fold line, a surface of the second panel is disposed in facing relationship and lays flush against a surface of the third panel, and the first set of strips of adhesive mate with the third set of strips of adhesive and the second set of strips of adhesive mate with the fourth set of strips of adhesive to form an envelope within an interior of the folded single ply of paper. 